Method of making lavatories or the like



10,1942 1-1.0. COORDES 2,272,511

METHOD OF MAKING LAVATORIES OR THE LIKE Filed Sept. 5, 1938 3 Sheets-Sheet 1 INVENTOR 6? CZordes Feb. 10, 1942. H. G. COORDES 2,212,511

' THOD OF MA I OR THE LIKE Sept 3, 1938 v IN VEN T 01? By .Zny a Czqrdes E E QJQ CJAM Feb. 10, 1942. H. e. gooRDEs 2,272,511

METHOD OF MAKING LAVATORIES OR THE LIKE Filed Sept. 3, 1958 s Shee ts- Sheet a Amt 1M INVENTOR' a a s BY Q w T RNE 5.

Patented Feb. 10, 1942 UNlTED STATES PTE nr cr es METHOD OF MAKING LAVATORIESOR' THE LIKE- 8 Claims. (c1. na -51) This invention relates to the art of fabricating manufacturing one-piece wash basins such as.

lavatories and the like.

It is among the objects of the present invention to devise a method of forming from a single blank of sheet metal a wash basin in which an outward ledge or border flange at the top of the sump extends inwardly of the latter to form a bead which projects into said sump.

Before explaining in detail the present invention it is to be understood that the invention is not limited in its application to the details of construction and arrangement of parts illustrated in the accompanying drawings, since the invention is capable of other embodiments and of being practiced or carried out in various ways. Also it is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation, and

it is not intended to limit the invention claimed herein beyond the requirements of the prior art.

In the drawings: Fig. 1 is a perspective view, partly in section, of a wash basin which is made according to the present invention.

Fig. 2 is a perspective view at a reduced scale of a blank of sheet metal after the first of a series of operations in the making of the wash basin has been performed thereon.

Fig. 3 shows the blank in perspective after the conclusion of another in said series of operations.

Fig. 4 is a perspective View of the blank ob-' tained by a modified step in said series of operations.

Fig. 5 is a perspective section through die mechanism for forming the inward bead at the top of the wash basin.

Fig. 6 is a fragmentary section through the same die mechanism, taken substantially on the line 6-6 of Fig. 5.

Fig. 7 is a section similar to that of Fig. 6, showing the elements of the mechanism in different positions of operation, however.

Fig. 8 is a greatly enlarged fragmentary section taken on the line 8-,8 of Fig. 7.

Fig. 9 is a perspective View of the basin after most of the operations have been performed.

Referring to the drawings, Fig. 1 shows one type of pressed metal washbasin made according to the present method. This washbasin I0 generally comprises a sump ll having a bottom [2 and upright walls [3 which are surrounded at the top by a continuous ledge or border flange .to receive faucets.

I l. Along the line of merger of certain upright walls l3 and the ledge I4 therev isv formed a bead 15 which projects into or overhangs-the sump II and serves not only to reenforce or stiifen the one-piece basin but also to reduce splashing of water from the sump over the ledge l4 thereof to a minimum. In the preferred type of wash basin shown in Fig. 1, the inwardly projecting bead I5 extends uninterruptedly around the front and sides of the sump. It is to be distinctly understood, however, that the present invention is not intended to'be limited to the disclosed extent of the bead l5 in Fig. 1, as the present method contemplates the formation of the bead along any one or more, or all, sides of the sump. -Extending from the top l6 of rear Wall 13 of the sump is an inclined splashboard ll which merges smoothly and gradually as at 18 into steeper end shoulders l9. Extending rearwardly from the top of the splashboard I1 and the shoulders 19 is a raised portion 14a of the ledge I4. A depending flange or apron 2! extends uninterruptedly around. the front and sides of the ledge l4 and also flanks the shoulders l9 and the ends of .the raised ledge portion Ida. The rear edgesiv of the apron 2| .and the ledge portion Ma, which form an inverted U, are bent inwardly to form, an uninterrupted flange 2; which lies in oneplane and serves for mounting purposes. The lower edge of the apron 2| is also .bent inwardly to form an uninterrupted flange 22 which is continuous with the rear flange 2| (1 but extends in a plane'which is substantially perpendicular to that in which said rear flange lies. A drain hole 23 is provided in the bottom 12 of the sump II, while a plurality of holes 24 in the splashboard I! are adapted In making the wash basin I9 (Fig. 1), the hereafter described steps in the deformation of a single blank of sheet metal are preferred, The blank is first subjected in any conventional die mechanism (not shown) to a drawing operation,

resulting in the formation .of the sump l I with a continuous plane outward flange Mb at the top. This same die mechanism may also be provided with a piercing punch to provide the drain hole 23 in the bottom of thelsump. Depending, on the-depth of draw of the sump ll during this first operation, the blank in Fig. 2 may at this stage need to be annealed so as to become sufliciently ductile again to withstand the further steps in the deformation of the blank.

Next, the blank is subjected in any suitable die mechanism (not shown) to a second-drawing operation, with the result that the flange or ledge portion M is raised above the rest of the flange |4b (Fig. 3) and the splashboard I1 with its end shoulders I9 is formed.

This second drawing operation may also be performed in a modified manner by suitable die mechanism (not shown) so that an intermediate strip |4d of the flange |4b, indicated in dotted lines in Fig. 2, is raised above said flange to Ho in the manner shown in Fig. 4 for the formation of the splashboard H with its end shoulders I9, the corresponding side portions 2|a of the apron 2| and the hidden flange along the rear edge of the raised ledge portion |4a. Moreover, substantially parallel beads 25, which. join the ends of the shoulders IS with the flange |4b, may be formed in this modified drawing operation. These beads 25 not only help to prevent the formation of wrinkles in the blank, but also constitute a continuation of the splashboard into the ledge I4.

Next, the blank is subjected to a beading operation in the mechanism shown in section in Figs. to '1, inclusive. The lower die plate 38 is suitably mounted on' the bolster plate of any suitable press (not shown), and is provided with a die pad 3| which is suitably guided for vertical movement and normally yieldingly urged into an uppermost position by pressure pins 32. The pad 3| has surfaces 33 and 34 which are so shaped as to accommodate the ledge portion |4b (Fig. 3) and the splashboard l1, including the shoulders |9, of the blank when the same is placed thereon. An auxiliary pad 35 (see also Figs. 6 and 7),

which is preferably a separate part, is mounted on the pad 3| and is of such shape as to coincide with the rear wall |3a and the bottom l2 of the sump when the blank is in place. Slidable between the pad 3| and the overhanging portion 35a of the auxiliary pad 35 are a plurality of beading dies 36, 31 and38 which are adapted to cooperate with counter dies 39, 48 and 4|, respectively, on a blank holder 42, mounted on a plate 43 which adapts said blank holder to the ram (not shown) of the press. The dies 36 to 4|,

inclusive, are shown in contracted or inoperative position in Fig. 6 in which the non-beaded blank is securely located on the pad 3|, the auxiliary pad 35 and the dies 31, as will be readily understood. Each of the inner dies 36, 31 and 38 is urged into the retracted position shown in Fig. 6 by a compression spring or springs which are similarly arranged as the spring 44 (Fig. 5) for the die 38. This spring 44, which is received in a groove 45 in the pad 3| and bears against a projecting pin 46 of the die 38, normally urges said die into retracted position in which it rests against a shoulder 41 of the auxiliary pad 35. The identical dies 36 are in turn urged by their springs (not shown) into the retracted position shown in Fig. 6 in which they engage the die 38. The remaining identical dies 31 are urged by their springs (not shown) into the retracted position shown in Fig. 6 in which their cam surfaces 48 and 49 engage corresponding surfaces 50 and 5|, respectively, of the die 38 and the dies 36, respectively. The dies 36 and 38 are provided with inclined surfaces of which the surface 52 of the die 38 is shown in Fig. 5. These inclined surfaces are adapted to cooperate with the correspondingly inclined cam surfaces 53 and 54 of a block 55 which is mounted on the lower die plate 38 and extends through an opening 56 in the pad 3| in the manner shown in Figs. 5 and 6.

The cam block 55 preferably bears against a 7 thrust pad 51 which is mounted on the auxiliary pad 35.

Adapted to cooperate with the inner dies 36, 31 and 38 are the outer dies 39, 48 and 4|, respectively, which are retained on the blank holder 42 and guided thereon for movement in the proper directions toward and away from their respective inner dies by any suitable means (not shown). Each of the outer dies 39, 48 and 4| is normally urged into the retracted position shown in Fig. 6 by a compression spring or springs which are similarly arranged as the compression spring 58 (Fig. 5) for the die 4|. This compression spring 58 is received in a groove 59 in the blank holder 42 and bears against a pin 68 which projects from the die 4|.

In home or rest position, the pad 3| with its auxiliary pad 35 and inner dies 36, 31 and 38 is held in uppermost position by the pressure pins 32, and the ram of the press and the blank holder 42 are also in their uppermost position.

holder 42 with the blank therebetween, the outer dies 39, 40 and'4l are forced inwardly into the position shown in Fig. 7, against the compression of their retracting springs such as 58. by cooperating cams 65 and 66. The cams 65 are movable with their respective outer dies 39, 48 and 4|,

while the cams 66 are mounted in the lower die plate 38. After the outer dies 39, 48 and 4| have been cammed inwardly into the position shown in Fig. 7 and while the pads 3 35 and the blank holder 42 continue their descent into the lowermost position shown in Fig. 5, the inclined surfaces, such as 52 (Fig. 5), of the inner dies come to cooperate with the cam surfaces 53 and 54 of the block 55. This results in outward movement of the inner dies into the position shown in Fig. '7, i. e., into cooperative relation with their corresponding outer dies 39, 48 and 4|, thereby forming the uninterrupted bead |5 which projects into the sump H of the wash basin. While the cam block 55 forces only the dies 36 and 38 outwardly, it will be understood that their cam surfaces 5| and 50, respectively, cooperate with the respective surfaces 49 and 48 of the dies 31 and force the latter outwardly simultaneously with the dies 36 and 38. Hence, when the blank emerges from the present mechanism, it will have the form shown in Fig. 3.

Referring to Fig. 8, it will be seen that the front wall |3b of the sump I is only of the preliminary shape or profile shown in dotted lines when the blank emerges from the described first drawing operation in which the sump is formed. More particularly, this front wall of preliminary shape extends upwardly at little or no curvature and merges into the smoothly rounded corner 18, that leads into the bottom |2 of the sump H, at an abrupt bend 1|. The inner dies 31, 38 and their respective outer'dies 48 and 4| cooperate to press said front wall |3b into the final shape shown in full lines in Fig. 8. In other words, the dies 31, 38,48 and 4| cooperate to form the front wall |3b of the sump into the desired shape or curvature of which the previously rounded corner 7|! is a part. The opposite side walls |3c of the sump are likewise formed into a preliminary shape only during the first drawing operation, to be finish-shaped by the cooperating dies 36, 39 and 37, 40 in substantially the same manner as the front wall I322. Inasmuch as the die pad 3| and the inner dies 36, 31 and 38 together define the desired inner contour of the bead l5, and the outer dies 39, 40 and 4| define the outer contour of said bead, the latter will be of a desired smooth curvature which may be uniform throughout its length or varied at will by correspondingly shaping the dies.

On a completed work stroke of the ram, the

' blank holder rises to its uppermost position, permitting the die pad 3| with its auxiliary pad 35 and inner dies 36, 31 and 38 to return to normal uppermost position. During the upward movement of the die pad 3|, the inner dies move out of cooperation with the cam block 55 and are spring-retracted into the position shown in Fig. 6 in which the beaded blank may be readily removed and a new blank placed for the next beading operation.

Next, the edges of the blank are preferably trimmed by any suitable mechanism (not shown), whereupon the outer margins of the flange portions Mb, I40 and of the shoulders l9 (Fig. 3)

are formed in any suitable die mechanism (not shown) into the depending apron 2|.

The washbasin is thereafter subjected to a fianging operation in any suitable die mechanism (not shown) which forms the uninterrupted inward flange 22 along the front and sides of the apron 2|, as well as the U-flange 2|a at the rear edges of the apron 2| and the raised ledge portion Ida. The faucet holes 24 may then be punched into the splashboard I! by any suitable mechanism (not shown).

To protect the washbasin against rusting and to enhance its pleasing appearance, a coat of enamel or similar substance is applied to the washbasin.

While the drawings disclose the formation of an inward or overhanging bead in a washbasin of the lavatory type, it is to be distinctly understood that the present method of providing the bead and the disclosed apparatus for making the same are not limited to this type of wash basin but can be used for beading other types of basins.

I claim:

1. In a method of making wash basins or the like, the steps of deforming a single metal sheet into a sump having an outward flange projecting from an upright portion of a side wall of said sump which has another portion merging at a curvature into the sump bottom, and outwardly pressing said upright portion into a desired curved profile of which the curvature of said other portion is a part while holding said flange immovable, thereby obtaining between said side wall and flange a bead which projects into said sump.

2. In a method of making basin containing articles, the steps of drawing a single metal sheet to provide a relatively deep basin therein having a bottom and an outward flange projecting from the upper edge of an upright side wall of said basin, and forcing said wall outwardly while holding said bottom and said flange and its place of juncture with said wall substantially immovable to provide a bead at said juncture projecting inwardly and overhanging said wall.

3. In a method of making basin containing articles, the steps of drawing a single metal sheet to provide a relatively deep basin therein having an outward flange projecting from the upper edge of an upright side wall of said basin, and forcing a portion of said wall outwardly while holding the bottom of the basin against collapsing and the place of juncture of said wall portion and flange substantially against outward movement to provide at said juncture a bead extending inwardly of said wall.

4. In a method of making basin containing articles, the steps of drawing a single metal sheet to provide a relatively deep basin therein having a continuous outward flange projecting from the upper edges of three upright walls of said basin around three sides thereof, and simultaneously forcing portions of said walls outwardly while holding the bottom of the basin against collapsing and the places of juncture of said portions and said flange substantially immovable to provide acontinuous bead at said junctures projecting inwardly of the basin.

5. In a method of making basin containing articles, the steps of drawing a single metal sheet to provide a relatively deep basin therein having a continuous outward flange projecting from the upper edges of three upright walls of said basin around three sides thereof, and simultaneously forcing portions of said walls outwardly while holding the bottom of the basin against collapsing and the places of juncture of said walls and flange substantially against outward movement to provide at said junctures a continuous bead extending inwardly of said walls.

6. In a method of making basin containing articles, the steps of deforming a single metal sheet into a sump having an outward flange projecting from an upright portion of a side wall of said sump which has another portion merging at a curvature into the sump bottom, and outwardly pressing said upright portion into a desired curved profile of which the curvature of said other portion is a part while holding said flange substantially against outward movement thereby providing between said side wall and flange a bead which projects into said sump.

7. In a method of making basin containing articles, the steps of drawing a metal sheet to provide a basin therein having a continuous outward flange projecting from theupper edges of the four upright walls of said basin, and simultaneously forcing a plurality of said walls outwardly while holding the bottom of the basin against collapsing and the places of juncture of said last named walls and the flange substantially against outward movement to provide beads at said junctures projecting inwardly of the basin.

8. In a method of making basin containing articles, the steps of drawing a metal sheet to provide a basin therein having a continuous outward flange projecting from the upper edges of the four upright walls of said basin, and holding the bottom of the basin against collapsing and the places of juncture of said flange and a plurality of said walls substantially against outward movement while at the same time forcing portions of said last named walls outwardly to provide heads at said junctures projecting inwardly of the basin.

HARRY G. COORDES. 

